Was asked to made a picture frame that folds up as a room divider, or Shoji Screen. This was a fun build I would have done a few thing different if I did another one. I would assembled the rails and styles together, then used a rabbet bit and router. The only reason I didn’t do it this time was the rails are not the same thickness and would have been difficult to line the router bit. After the project I think it would have been easier then the rout I took. In the end the project still worked out and the customer, my brother, was still pleased. The Shoji Screen sits in his photography studio. Studio 58 in Cincinnati. Check it out on FB.
I cut 11, 18″x 12″ 1/8″ hard board panels. I used 9 for the project and 2 for spares and jigs.
Cut all the long styles to length and width.
The rails was all the same size. The middle one needed rabbet on both sides. The top and bottom needed rabbets on one side. All cut to length using the cross cut sled. The rabbets was made with a dado blade and superficial fence.
On the top and bottom, I cut this detail. with a jig saw. The touched it up with the disc sander.
I place a stop bock down. Butted up one rail then place all the pieces down for the lay out. Mark all the joints for dowels and rabbets.
On the fence I marked start and stop locations of the blade. I have the lay outs marked on the rails. carefully drop the rails on the line into the blade. Move the piece till the next line and repeat. Line up the line with the dowel jig, drill the 1/4″ holes. Then insert the dowels.
Assembly the piece with glue, then repeat two more times. The middle two rails get ripped in half.
Now you should have three panels.
The right middle Rails gets two hinges to the outside. The left middle rails get hinges on the inside.
This jig was created to hold a multi-tool to cut slot to hold the buttons in the rails.
Dewalt Drill 20V Max: http://amzn.to/2jLzD2s
Dewalt Oscillating Multi Tool – http://amzn.to/2kyANvn
Dewalt Oscillating Acc Kit – http://amzn.to/2jCKoBk
Self Centering Doweling Jig – Dowelhttp://amzn.to/2kyukAq
Drill Bit Stop Collar – http://amzn.to/2kyulEq
Self Cetering Drill Bit – http://amzn.to/2kyyng0
Pop Rivet Gun – http://amzn.to/2kyR1ok
The buttons is held on by rivets. They turn into the slots to hold the panel in place.